Base fabric for carpets



Dec. 20, 1966 w. GEORGII ETAL BASE FABRIC FOR CARPETS Filed June 5, 1964Fig.4

INVENTOR:

United States latent C) 3,293,103 BASE FABRIC FOR CARPETS Walter Georgiiand Herbert Georgii, Sindelfingen, near Stuttgart, Germany, assiguors toZweigart & Sawitzkr, Sindelfingen, near Stuttgart, Germany Filed June 5,1964, Ser. No. 372,806 Claims priority, applicatiim Ggrmany, June 10,1963,

Z 6 Claims. (Cl. 161-90) The present invention relates to a base fabricfor knotted carpets and to the method of making the same. Moreparticularly, the present invention relates to a woven base fabric whichis suited for hand made Smyrna rugs, Rya rugs and similar rugs orcarpets.

Known base fabrics serving this purpose, for example, so-calledSmyrna-Stramin base fabrics are woven of pairs of parallel threads in aplain basket weave so that substantially square openings are formed. Thewool tufts are inserted into the openings, and knotted to the doublethreads.

The design of rugs of this type is made according to design patternswhich show points corresponding to the openings in different colors, andsuch points are counted and the tufts are accordingly inserted intocounted openings of the base fabric. The design pattern also indicateshow many knots are to be made in each row. Usually the colors of thecarpet are printed, or painted on the design pattern, or if the same isblack and white, the colors are indicated according to point numbers.

Another base fabric particularly intended for Turkestan rugs has coloredthreads woven in accordance with the intended color design of thefinished rug, and correspondingly colored tufts are knotted to woventhreads of the base fabric having the same colors.

The knotting into the narrow openings of the base fabric according tothe prior art is difficult, and the preparation of the colored designpatterns is expensive. Furthermore, careful counting is required formost base fabrics.

It is the object of the present invention to overcome the disadvantagesof known base fabrics for rugs or carpets, and to provide a base fabricwhich can be inexpensively manufactured, but which permits attachment oftufts in a very simple operation.

Another object of the invention is to provide a base fabric with loopsinto which the tufts can be inserted in a simple operation.

Another object of the invention is to provide a carpet base fabric whichcan be woven on a Jacquard machine, and indicates by straight linesdetermined by the threads of the fabric the contours of the coloreddesign pattern of the rug or carpet.

Another object of the invention is to eliminate the painting, printing,or other application of a design on the base fabric.

Another object of the invention is to provide a carpet base fabricrequiring no counting by the operator for the application of the tuftsin accordance with a predetermined design.

Another object of the invention is to provide a carpet base fabric whichis particularly suited for the knotting of tufts by a book, so that theoperator is not tired by the work.

Another object of the invention is to provide a carpet base fabric whichresults in a finished carpet requiring no lining of the back when theknotting operation has been completed. I

Another object of the invention is to provide a base fabric of suchstiffness that the loops by which the tufts are held can be spaced greatdistances from each other.

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With these objects in view, a woven carpet base fabric according to theinvention comprises weft and warp threads woven in a distinguishablepattern and anchoring threads woven into the base fabric and formingloops thereon .so that the tufts can be easily inserted into the loopsand knotted to the same avoiding the difficulty of knotting the tufts tothe weft or warp threads.

In the preferred embodiment of the invent-ion, first and second sets ofwarp threads and weft threads are interwoven in superimposed front andback layers in which the first and second sets alternate in adistinguishable pattern. The anchoring threads are preferably woven onlyinto the back layer, and form floating loops on the front layer, eachfloating loop being located on one of the design portions.

The loops must be somewhat loose as compared with the woven base so thatthe base is not warped when the wool tufts are tied to the loops. Whenthe tufts are tied, the loop threads are fixed in the respectiveposition thereof, so that all loops are longer than the distance betweenthe ends of the loops on the woven base, and such difference in lengthshould be the same for all loops. In order to facilitate the manufactureof the base fabric, the anchoring threads which form the loops for thetufts, extend in weft direction, and are correspondingly woven into thebase fabric.

In the preferred embodiment of the invention, two pairs of anchoringthreads are provided which form loops, and are woven into the back layerof the base fabric. If the design requires more than two colors, acorresponding multiple weave is provided.

In accordance with the method of the present invention, the woven basefabric is shrunk to a greater extent than the anchoring threads so thatthe loops are wide enough for insertion of the tufts. The base fabric istreated with a sizing material to increase its stiffness and rigidity,but the loops are not exposed to the sizing material to prevent asticking of the loops to the base fabric which would prevent theinsertion of the tufts into the loops.

It is also advantageous to apply to the back face of the base fabric anon-skid substance, such as latex so that slipping of the rug isprevented, and the knotting of the tufts is facilitated since the fabriccannot slip during the insertion of the tufts.

The novel features which are considered as characteristic for theinvention are set forth in particular in the appended claims. Theinvention itself, however, both as to its construction and its method ofoperation, together with additional objects and advantages thereof, willbe best understood from the following description of specificembodiments when read in connection with the accompanying drawings, inwhich:

FIG. 1 is a fragmentary schematic plan view of a base fabric accordingto the invention shown on an enlarged scale; and

FIG. 2 is a fragmentary cross-section view on an enlarged scale taken online IIII in FIG. 1.

Referring now to the drawing, the woven base 1 is double-woven of afirst set of warp threads 2 and weft threads 3 and of a second set ofwarp threads 2 and weft threads 3 which form a front layer 4 and a backlayer 5. The first and second sets are interwoven in distinguishableportions 14 having different colors and are alternately located in thefront layer 4 and in the back layer 5. In FIG. 1, twelve rectangularportions 14 are schematically indicated by crossing imaginary lines AAand BB. Since the two sets of threads 2, 3 and 2', 3 have differentcolors, the portions 14 of the pattern formed in the front layer bythreads 2, 3- are clearly distinguishable on the front and back faces ofthe fabric.

Each rectangular portion 14 has an area receiving a single tuft 15.

Two pairs of anchoring threads 6, 7 and 8, 9 are woven into the backlayer and form loops 11 on the front face 1%) of the front layer 4. Thewidth of each pair of loops 11 in weft direction is the same andcorresponds to the Width of a rectangular portion of the front layer ofthe base fabric woven of the first set of threads 2, 3, or of the secondset of threads 2, 3'. Each pair of anchoring threads is interwoven withthe warp and weft threads of the base fabric so that the anchoringthreads 6, 7 form floating loops over spaced fabric portions formed inthe front layer by warp threads 2 and weft threads 3', and are woveninto the adjacent portions formed in the back layer by threads 2' and3'. The pair of anchoring threads 8, 9 forms a pair of floating loopsover a portion 14 formed by the threads 2, 3 in the front layer, and arewoven into the alternate portions 14 of the back layer. The Weave of theanchoring threads corresponds somewhat to a sateen weave but theanchoring threads are interwoven with a plurality of warp threads 2 or 2in the back layer in a plain weave corresponding to a weft thread so asto be held and tied by the warp threads. Due to the symmetrical weave, aportion of the pair of anchoring threads 6, 7 which is woven into theback layer 5 is located opposite a loop of the respective other pair ofanchoring threads 8, 9 located on the front face of the front layer 4.

The distinguishable pattern portions 14 formed by the two sets ofthreads 2, 3 and 2, 3 are small squares, and one pair of loops 11 islocated on each square, preferably at the center thereof, to hold a tufton the respective square pattern portion.

When the base fabric including the anchoring threads is woven on a loom,the loops lie flat on the front face 10 of the base weave, andconsequently it is difiicult to insert the tuft yarns.

In accordance with the method of the present invention, a certainlooseness of the loops is achieved by treating the fabric in such amanner that the woven base fabric shrinks more than the loops 11. Thefabric is treated with a liquid so that the tightly woven threads of thedouble weave formed by the threads 2, 3 and 2, 3' shrink more than theloop threads. Thereupon, the fabric is permitted to dry on a frame inslightly stretched condition, and finally the woven base fabric istreated with a'sizing material to increase its rigidity and stiffness asis suitable for a carpet or rug. The front face 10 and the loops 11thereon must not be exposed to the sizing material since otherwise theloops would stick to the base fabric and insertion of the wool tuftsinto the loops would not be possible. A further advantage is that theloops retain their original strength and resistance against tearing notweakened by the application of the sizing material. The threads 2, 3 and2', 3' are preferably cotton threads.

The back face of the back layer is preferably treated with a substance,such as latex which increases its friction so that a skidding of the rugor carpet is prevented.

It will be understood that each of the elements described above, or twoor more together, may also find a useful application in other types ofbase fabrics for rugs or carpets difiering from the types describedabove.

While the invention has been illustrated and described as embodied in abase fabric for a hand made carpet or rug having floating loops for theanchoring of wool tufts, it is not intended to be limited to the detailsshown, since various modifications and structural changes may be madewithout departing in any way from the spirit of the present invention.

Without further analysis, the foregoing will so fully reveal the gist ofthe present invention that others can by applying current knowledgereadily adapt it for various applications without omitting featuresthat, from the standpoint of prior art, fairly constitute essentialcharacteristics of the generic or specific aspects of this inventionand, therefore, such adaptations should and are intended to becomprehended within the meaning and range of equivalence of thefollowing claims.

What is claimed as new and desired to be secured by Letters Patent is:

1. A woven carpet base fabric comprising a first set of war-p threadsand weft threads and a second set of warp threads and weft threadsinterwoven in superimposed front and back layers in which said first andsecond sets form pattern portions; and first and second pairs ofanchoring threads, woven into said back layer and forming floating loopson said front layer, said first pair of anchoring threads being woveninto said first set of weft threads and warp threads and said secondpair of anchoring threads being woven into said second set of weftthreads and warp threads where the same are located in said back layer,and forming pairs of floating loops where the respective set of warpthreads and weft threads forms said pattern portions of said frontlayer, said loops being adapted to hold tufts on said front layer, pairsof said loops being aligned and spaced from other pairs of said loops adistance corresponding to a plurality of said threads of said first andsecond sets of threads.

2. A woven carpet base fabric comprising a first set of warp threads andweft threads and a second set of Warp threads and weft threadsinterwoven in superimposed front and back layers in which said first andsecond sets form pattern portions; and first and second pairs ofanchoring threads, woven in weft direction into said back layer andforming floating loops on said front layer, said first pair of anchoringthreads being woven into said first set of weft threads and warp threadsand said second pair of anchoring threads being woven into said secondset of weft threads and warp threads where the same are located in saidback layer, and forming pairs of floating loops where the respective setof warp threads and weft threads forms said pattern portions of saidfront layer, said loops being adapted to hold tufts on said front layer,pairs of loops of said first and second anchoring threads being alignedin weft direction and spaced from other pairs of loops a distancecorresponding to a plurality of weft threads of said first and secondsets.

3. A woven carpet base fabric according to claim 2 and comprising acoating of a sizing material adhering to said weft threads and warpthreads only.

4. A woven carpet base fabric comprising a first set of Warp threads andweft threads having one prevailing color and a second set of warpthreads and weft threads having a different prevailing color andinterwoven i'n superimposed front and back layers in which said firstand second sets form pattern portions; and first and second pairs ofanchoring threads, woven in weft direction into said back layer andforming floating loops on said front layer, said first pair of anchoringthreads being woven into said first set of weft threads and warp threadsand said second pair of anchoring threads being woven into said secondset of weft threads and warp threads where the same are located in saidback layer, and forming pairs of floating loops where the respective setof warp threads and weft threads forms said pattern portions of saidfront layer, said loops being adapted to hold tufts on said front layer,pairs of loops of said first and second anchoring threads being alignedin weft direction and spaced from other pairs of loops a distancecorresponding to a plurality of weft threads of said first and secondsets.

5. A woven carpet base fabric comprising a first set of warp threads andweft threads and a second set of warp threads and weft threadsinterwoven in superimposed front and back layers, said first and secondsets forming pattern portions in each of said layers, said warp threadsand Weft threads extending in two perpendicular directions; andanchoring threads woven into said back layer and forming floating loopson said front layer adapted to hold tufts passing through said floatingloops, said floating loops extending in one of said directions over saidpattern portions, and being spaced in the other direction from otherfloating loops a distance corresponding to a plurality of said threadsof said first and second sets of threads.

6. A woven carpet base fabric comprising a first set of warp threadshaving one prevailing color and a second set of warp threads and weftthreads having a different prevailiug color, said sets being interwovenin superimposed front and back layers, said first and second setsforming pattern portions in each of said layers, said Warp threads andweft threads extending in tWo perpendicular directions; and anchoringthreads woven into said back layer and forming floating loops on saidfront layer adapted to hold tufts passing through said floating loops,said floating loops extending in one of said directions over saidpattern portions, and being spaced in the other direction from otherfloating loops a distance corresponding to a plurality of said threadsof said first and second sets of threads.

References Cited by the Examiner UNITED STATES PATENTS 267,285 11/1882Urbahn 139394 881,386 3/1908 Earnshaw 139413 1,991,366 2/1935 Barrell139410 2,180,054 11/1939 Hindle et al 139408 2,864,409 12/1958 Richter139408 2,949,660 8/1960 Rice 28-74 3,015,149 1/1962 Foster et a1.139-391 3,075,274 1/ 1963 Mizell 28-74 FOREIGN PATENTS 813,158 2/1937France.

MERVIN STEIN, Primary Examiner.

ROBERT R. MACKEY, DONALD W. PARKER,

Examiners.

H. S. JAUDON, Assistant Examiner.

1. A WOVEN CARPET BASE FABRIC COMPRISING A FIRST SET OF WRAP THREADS ANDWEFT THREADS AND A SECOND SET OF WRAP THREADS AND WEFTS THREADSINTERWOVEN IN SUPERIMPOSED FRONT AND BACK LAYERS IN WHICH SAID FIRST ANDSECOND SETS FORM PATTERN PORTIONS; AND FIRST AND SECOND PAIRS OFANCHORING THREADS, WOVEN INTO SAID BACK LAYER AND FORMING FLOATING LOOPSON SAID FRONT LAYER, SAID FIRST PAIR OF ANCHORING THREADS BEING WOVENINTO SAID FIRST SET OF WEFT THREADS AND WRAP THREADS AND SAID SECONDPAIR OF ANCHORING THREADS BEING WOVEN INTO SAID SECOND SET OF WEFTTHREADS AND WRAP THREADS WHERE THE SAME ARE LOCATED IN SAID BACK LAYER,AND FORMING PAIRS OF FLOATING LOOPS WHERE THE RESPECTIVE SET OF WRAPTHREADS AND WEFT THREADS FORMS SAID PATTERN PORTIONS OF SAID FRONTLAYER, SAID LOOPS BEING ADAPTED TO HOLD TUFTS ON SAID FRONT LAYER, PAIRSOF SAID LOOPS BEING ALIGNED AND SPACED FROM OTHER PAIRS OF SAID LOOPS ADISTANCE CORRESPONDING TO A PLURALITY OF SAID THREADS OF SAID FIRST ANDSECOND SETS OF THREADS.